Patterned substrate, electro-optical device, and method for manufacturing an electro-optical device

ABSTRACT

A patterned substrate has a laminated pattern having laminating patterns formed by drying droplets containing a pattern formation material. A lower layer pattern contains a surfactant that is lyophilic with respect to droplets that form an upper layer pattern.

BACKGROUND

1. Technical Field

The invention relates to a patterned substrate, an electro-optical device, and a method for manufacturing an electro-optical device.

2. Related Art

Known displays equipped with light emitting elements include organic electroluminescence displays (organic EL displays) used as an electro-optical device equipped with an organic electroluminescence element (organic EL element).

Methods for manufacturing organic EL elements are generally classified by the kind of material that makes up its organic EL layer thereof. When the material that makes up the organic EL layer is a low-molecular weight organic material, a vapor phase process is utilized, in which the organic EL layer is formed by the vapor deposition of this low-molecular weight organic material. On the other hand, when the material that makes up the organic EL layer is a high-molecular weight organic material, a liquid phase process is utilized, in which the high-molecular weight organic material is dissolved in an organic solvent or the like, and a coating of this solution is applied and dried.

With an inkjet method, which is a type of liquid phase process, tiny droplets of solution are discharged, so the location where the organic EL layer is formed, the film thickness, and the like can be controlled more precisely than with other liquid phase processes (such as spin coating). Furthermore, since an inkjet method involves discharging the droplets only in the region where the organic EL layer is to be formed (the element formation region), the high-molecular weight organic material (the raw material) can be used in a smaller amount.

With an inkjet method, however, as the contact angle of the droplets increases with respect to the element formation region (that is, as wettability decreases), the discharged droplets end up clumping in just one part of the pattern formation region. As a result, depending on the boundary between droplets and other factors, this can lead to problems such as a loss of uniformity of shape (such as the film thickness uniformity of the organic EL layer, or the film thickness uniformity between organic EL layers).

In view of this, it has been proposed in the past that the wettability of the discharged droplets be improved in an inkjet method (see JP-A-2002-334782, for example). In JP-A-2002-334782, the pattern formation region (over the transparent electrode) is subjected to a lyophilic plasma treatment (oxygen plasma treatment) before the droplets are discharged. This improves the wettability of the droplets and increases the uniformity of the pattern shape within the pattern formation region.

In general, an organic EL layer is formed from a laminated pattern having at least a light emitting layer that emits colored light and a hole transport layer formed between this light emitting layer and an anode (such as an ITO film). When a laminated pattern such as this is formed, with an inkjet method, the upper layer pattern and the lower layer pattern are made of materials with different polarity in order to prevent the lower layer pattern from dissolving into the droplets that form the upper layer pattern. For example, the upper layer pattern is formed by dissolving or dispersing a lipophilic light emitting material in an aromatic organic solvent, and the lower layer pattern is formed by dissolving or dispersing a hydrophilic hole transport layer in water.

In other words, a material with low wettability with respect to the lower layer pattern is selected for the material that forms the upper layer pattern. Accordingly, the lower layer pattern has to be subjected to the above-mentioned lyophilic plasma treatment in order to ensure the wettability of the droplets that form the upper layer pattern.

However, since the lower layer pattern (such as a hole transport layer) is formed from an organic substance with low plasma resistance, a problem is that subjecting this lower layer pattern to a plasma treatment or the like can damage the lower layer pattern. Another problem is that tacking on this plasma treatment step results in correspondingly lower productivity of the organic EL display.

SUMMARY

It is an advantage of the invention to provide a patterned substrate, an electro-optical device, and a method for manufacturing an electro-optical device, with which the uniformity of a laminated pattern formed by drying droplets is increased, and the productivity thereof is improved.

The patterned substrate of an aspect of the invention includes a laminated pattern formed by laminating patterns formed by drying droplets containing a pattern formation material, wherein the lower layer pattern contains a surfactant that is lyophilic with respect to the droplets that form the upper layer pattern.

With the patterned substrate of the invention, the surfactant contained in the lower layer pattern improves the wettability of the droplets forming the upper layer pattern with respect to the lower layer pattern. Therefore, an upper layer pattern of uniform shape can be laminated over the lower layer pattern without having to add any surface treatment step or the like. This in turn allows the productivity of the patterned substrate to be increased.

It is preferable that the surfactant in this patterned substrate include a functional group that is lyophilic with respect to the droplets that form the upper layer pattern, and a functional group that is lyophilic with respect to the droplets that form the lower layer pattern.

With this patterned substrate, since the surfactant includes a functional group that is lyophilic with respect to the droplets that form the lower layer pattern, this surfactant can be uniformly mixed into the droplets that form the lower layer pattern. Also, since the surfactant has a functional group that is lyophilic with respect to the droplets that form the upper layer pattern, this surfactant is capable of improving the wettability of the droplets that form the upper layer pattern. Therefore, the upper layer pattern can be laminated in a uniform shape over the lower layer pattern, and the productivity of the patterned substrate can be increased.

It is preferable that the surfactant in this patterned substrate be an organic compound including a hydrophilic functional group and a lipophilic functional group. For example, a hydrolyzate of silane coupling agent having a functional group that is lyophilic to the droplets that form the upper layer pattern can be utilized.

It is preferable that the pattern formation material in this patterned substrate be a light emitting element formation material, and the laminated pattern is a light emitting element.

With this patterned substrate, a light emitting element can be formed in a uniform shape, and the productivity of a patterned substrate equipped with this light emitting element can be increased.

The electro-optical device of another aspect of the invention is equipped with a light emitting element formed by laminating thin film layers formed by drying droplets containing a thin film layer formation material, wherein the lower thin film layer contains a surfactant that is lyophilic with respect to the droplets that form the upper thin film layer.

With the electro-optical device of this aspect of the invention, the surfactant contained in the lower thin film layer can improve the wettability of the droplets that form the upper thin film layer with respect to the lower thin film layer. Therefore, an upper thin film layer having a more uniform shape can be laminated over the lower thin film layer without having to add any surface treatment step. This in turn allows the productivity of the electro-optical device to be increased.

It is preferable that the surfactant in this electro-optical device include a functional group that is lyophilic with respect to the droplets that form the upper thin film layer, and a functional group that is lyophilic with respect to the droplets that form the lower thin film layer.

With this electro-optical device, because the surfactant includes a functional group that is lyophilic with respect to the droplets that form the lower thin film layer, this surfactant can be more uniformly mixed into the droplets that form the lower thin film layer. Also, since the surfactant includes a functional group that is lyophilic with respect to the droplets that form the upper thin film layer, this surfactant can be more uniformly mixed into the droplets that form the upper thin film layer. Therefore, an upper thin film layer having a more uniform shape can be laminated over the lower thin film layer, and the productivity of the electro-optical device can be increased.

It is preferable that the surfactant in this electro-optical device be an organic compound including a hydrophilic functional group and a lipophilic functional group. For example, a hydrolyzate of silane coupling agent having a functional group that is lyophilic to the droplets that form the upper layer can be utilized.

It is preferable that the light emitting element in this electro-optical device be an electroluminescence element produced by laminating the thin film layers between a transparent electrode and a back electrode.

With this electro-optical device, the productivity of an electro-optical device equipped with an electroluminescence element can be increased.

It is preferable that the light emitting element in this electro-optical device be an organic electroluminescence element including the above-mentioned thin film layers composed of an organic material.

With this electro-optical device, the productivity of an electro-optical device equipped with an organic electroluminescence element can be increased.

It is preferable that the upper thin film layer in this electro-optical device be a light emitting layer composed of a light emitting layer formation material that can be dissolved or dispersed in a hydrophobic liquid, and that the lower thin film layer be a hole transport layer composed of a hole transport layer formation material that can be dissolved or dispersed in a hydrophilic liquid.

With this electro-optical device, because a hole transport layer that can be dissolved or dispersed in a hydrophilic liquid contains a surfactant, a light emitting layer that can be dissolved or dispersed in a hydrophobic liquid can be more uniformly laminated over this hole transport layer.

The method for manufacturing an electro-optical device of still another aspect of the invention is a method in which thin film layers are formed by drying droplets containing a thin film layer formation material, and these thin film layers are laminated to form a light emitting element. The method includes mixing a surfactant that is lyophilic with respect the droplets that form an upper thin film layer into droplets that form the lower thin film layer; and drying the droplets in which this surfactant has been mixed to form the lower thin film layer, and then drying the droplets that form the upper thin film layer on the lower thin film layer to laminate the upper thin film layer over the lower thin film layer.

With the method for manufacturing an electro-optical device of the invention, the surfactant mixed into the droplets that form the lower thin film layer improves the wettability of the droplets that form the upper thin film layer with respect to the lower thin film layer. Therefore, an upper thin film layer of uniform shape can be laminated over the lower thin film layer without having to add any surface treatment step. This in turn allows the productivity of the electro-optical device to be increased.

It is preferable that the surfactant in this method for manufacturing an electro-optical device include a functional group that is lyophilic with respect to the droplets that form the upper layer pattern, and a functional group that is lyophilic with respect to the droplets that form the lower layer pattern.

With this method for manufacturing an electro-optical device, because the surfactant includes a functional group that is lyophilic with respect to the droplets that form the lower thin film layer, this surfactant can be more uniformly mixed into the droplets that form the lower thin film layer. Also, since the surfactant includes a functional group that is lyophilic with respect to the droplets that form the upper thin film layer, this surfactant can be more uniformly mixed into the droplets that form the upper thin film layer. Therefore, an upper thin film layer of uniform shape can be laminated over the lower thin film layer, and the productivity of the electro-optical device can be increased.

It is preferable that the surfactant in this method for manufacturing an electro-optical device be an organic compound including a hydrophilic functional group and a lipophilic functional group. For example, a silane coupling agent having a functional group that is lyophilic to the droplets that form the upper layer pattern can be utilized.

It is preferable that the light emitting element in this method for manufacturing an electro-optical device be an electroluminescence element produced by laminating the thin film layers between a transparent electrode and a back electrode.

With this method for manufacturing an electro-optical device, the productivity of an electro-optical device equipped with an electroluminescence element can be increased.

It is preferable that the light emitting element in this method for manufacturing an electro-optical device is an organic electroluminescence element having the above-mentioned thin film layers composed of an organic material.

With this method for manufacturing an electro-optical device, the productivity of an electro-optical device equipped with an organic electroluminescence element can be increased.

In this method for manufacturing an electro-optical device, it is preferable that the surfactant be mixed into a hydrophilic liquid containing a hole transport layer formation material, and the droplets of the liquid in which the surfactant has been mixed are dried to form a hole transport layer that is the lower layer, after which a hydrophobic liquid containing a light emitting layer formation material is dried over the hole transport layer to laminate a light emitting layer that is the upper layer.

With this method for manufacturing an electro-optical device, because the hole transport layer contains a surfactant, a water-repellant liquid containing a light emitting layer formation material can wet and spread out over a hole transport layer formed by drying hydrophilic droplets, and a light emitting layer can be laminated uniformly. Therefore, the productivity of an electro-optical device equipped with an organic electroluminescence element composed of a hole transport layer and a light emitting layer can be increased.

In this method for manufacturing an electro-optical device, it is preferable that the main component of the above-mentioned hydrophilic liquid be a polar liquid, and that the main component of the above-mentioned hydrophobic liquid be a non-polar liquid.

With this method for manufacturing an electro-optical device, a light emitting layer formed by drying a non-polar liquid can be uniformly laminated over a hole transport layer formed by drying a polar liquid.

In this method for manufacturing an electro-optical device, it is preferable that the droplets be discharged from a droplet discharge apparatus.

With this method for manufacturing an electro-optical device, because fine droplets are formed by a droplet discharge apparatus, a light emitting element can be formed in a more uniform shape, and the productivity of an electro-optical device can be increased.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified plan view of an organic EL display that is an embodiment of the invention;

FIG. 2 is a simplified plan view of pixels in the same;

FIG. 3 is a simplified cross section of the control element formation region in the same;

FIG. 4 is a simplified cross section of the control element formation region in the same;

FIG. 5 is a simplified cross section of the light emitting element formation region in the same;

FIG. 6 is a flowchart of the steps of manufacturing an electro-optical device;

FIG. 7 is a diagram illustrating the steps of manufacturing an electro-optical device;

FIG. 8 is a diagram illustrating the steps of manufacturing an electro-optical device;

FIG. 9 is a diagram illustrating the steps of manufacturing an electro-optical device; and

FIG. 10 is a diagram illustrating the steps of manufacturing an electro-optical device.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Specific embodiments of the invention will now be described through reference to FIGS. 1 to 10. FIG. 1 is a simplified plan view of an organic electroluminescence display (organic EL display) that serves as an electro-optical device.

As shown in FIG. 1, an organic EL display 10 is equipped with a transparent substrate 11 as a patterned substrate. The transparent substrate 11 is a non-alkaline glass substrate formed in the shape of a square, and a square element formation region 12 is formed on the surface thereof (element formation surface 11 a). In this element formation region 12, a plurality of data lines Ly are formed at a specific spacing and extending in the vertical direction (column direction). The data lines Ly are electrically connected to a data line drive circuit Dr1 disposed on the lower side of the transparent substrate 11. The data line drive circuit Dr1 produces a data signal on the basis of display data supplied from an external apparatus (not shown), and outputs this data signal at a specific timing to the data lines Ly corresponding to the data signal.

In the element formation region 12, a plurality of power lines Lv extending in the column direction are provided to the data lines Ly at a specific spacing. The power lines Lv are electrically connected to a common power line Lvc formed on the lower side of the element formation region 12, and drive power produced by a power supply voltage production circuit (not shown) is supplied to the power lines Lv.

A plurality of scanning lines Lx extending in the direction perpendicular to the data lines Ly and the power lines Lv (the row direction) are formed at a specific spacing in the element formation region 12. The scanning lines Lx are electrically connected to a scanning line drive circuit Dr2 formed on the left side of the transparent substrate 11. The scanning line drive circuit Dr2 selectively drives specific scanning lines Lx from among the plurality of scanning lines Lx at a specific timing on the basis of a scanning control signal supplied from a control circuit (not shown), and a scanning signal is outputted to the scanning lines Lx.

A plurality of pixels 13 arranged in a matrix are formed by connecting to the corresponding data lines Ly, power lines Lv, and scanning lines Lx where the data lines Ly and the scanning lines Lx intersect. A control element formation region 14 and a light emitting element formation region 15 are delineated within each of the pixels 13. The pixels 13 are protected by covering the top side of the element formation region 12 with a square sealing substrate 16 (the two-dot chain line in FIG. 1).

The pixels 13 in this embodiment are pixels that emit light of corresponding colors, and are either red pixels that emit red light, or green pixels that emit green light, or blue pixels that emit blue light. These pixels 13 are used to display a full-color image on the back side (display side 11 b) of the transparent substrate 11.

The pixels 13 will now be described. FIG. 2 is a simplified plan view of the layout of the control element formation region 14 and the light emitting element formation region 15. FIGS. 3 and 4 are simplified cross sections of the control element formation region 14 along the one-dot chain lines A-A and B-B, respectively, in FIG. 2. FIG. 5 is a simplified cross section of the light emitting element formation region 15 along the one-dot chain line C-C in FIG. 2.

First the structure of the control element formation regions 14 will be described. As shown in FIG. 2, a control element formation region 14 is formed on the lower side of each of the pixels 13, and a first transistor (switching transistor) T1, a second transistor (drive transistor) T2, and a holding capacitor Cs are formed in each control element formation region 14.

As shown in FIG. 3, the switching transistor T1 is equipped with a first channel film B1 at its lowermost layer. The first channel film B1 is a p-type polysilicon film formed in the shape of an island on the element formation surface 11 a, in the middle of which is formed a first channel region C1. Activated n-type regions (a first source region S1 and a first drain region D1) are formed flanking the first channel region C1 on the left and right sides. In other words, the switching transistor T1 is what is known as a polysilicon TFT.

A gate insulation film Gox and a first gate electrode G1 are formed on the upper side of the first channel region C1, in that order from the element formation surface 11 a. The gate insulation film Gox is a silicon oxide film or other such insulating film having optical transmissivity, and is deposited over substantially the entire surface of the element formation surface 11 a and the upper side of the first channel region C1. The first gate electrode G1 is a tantalum, aluminum, or other such low-resistance metal film, formed across from the first channel region C1, and is electrically connected to a scanning line Lx as shown in FIG. 2. As shown in FIG. 3, the first gate electrode G1 is electrically insulated by a first interlayer insulation film IL1 deposited on the upper side of the gate insulation film Gox.

When the scanning line drive circuit Dr2 inputs a scanning signal through the scanning line Lx to the first gate electrode G1, the switching transistor T1 is switched on by this scanning signal.

A data line Ly that goes through the first interlayer insulation film IL1 and the gate insulation film Gox is electrically connected to the first source region S1. A first drain electrode Dp1 that goes through the first interlayer insulation film IL1 and the gate insulation film Gox is electrically connected to the first drain region D1. As shown in FIG. 3, this data line Ly and first drain electrode Dp1 are electrically connected by a second interlayer insulation film IL2 deposited on the upper side of the first interlayer insulation film IL1.

The scanning line drive circuit Dr2 then successively selects the scanning lines Lx one at a time on the basis of line-order scanning, whereupon the switching transistor T1 of the pixel 13 is switched on in its turn and while selected. When the switching transistor T1 is switched on, the data signal outputted from the data line drive circuit Dr1 is outputted through the data line Ly and the switching transistor T1 (channel film B1) to the first drain electrode Dp1.

As shown in FIG. 4, the drive transistor T2 is a polysilicon TFT equipped with a second channel region C2, a second source region S2, and a second drain region D2. A second gate electrode G2 is formed via the gate insulation film Gox on the upper side of a second channel film B2 thereof. The second gate electrode G2 is a tantalum, aluminum, or other such low-resistance metal film, and as shown in FIG. 2, is electrically connected to a lower electrode Cp1 of the holding capacitor Cs and the first drain electrode Dp1 of the switching transistor T1. As shown in FIG. 4, the second gate electrode G2 and the lower electrode Cp1 are electrically connected by the first interlayer insulation film IL1 deposited on the upper side of the gate insulation film Gox.

The second source region S2 is electrically connected to an upper electrode Cp2 of the holding capacitor Cs that goes through the first interlayer insulation film IL1. As shown in FIG. 2, this upper electrode Cp2 is electrically connected to the corresponding power line Lv. In other words, as shown in FIGS. 2 and 4, the holding capacitor Cs, in which the first interlayer insulation film IL1 serves as a capacitance film, is connected between the second source region S2 and the second gate electrode G2 of the drive transistor T2. The second drain region D2 is electrically connected to a second drain electrode Dp2 that goes through the first interlayer insulation film IL1. The second drain electrode Dp2 and the upper electrode Cp2 are electrically connected by the second interlayer insulation film IL2 deposited on the upper side of the first interlayer insulation film IL1.

When the data signal outputted from the data line drive circuit Dr1 is outputted through the switching transistor T1 to the first drain region D1, the holding capacitor Cs stores a charge relative to the outputted data signal. Then, when the switching transistor T1 is switched off, a drive current relative to the charge stored in the holding capacitor Cs is outputted through the drive transistor T2 (channel film B2) to the second drain region D2.

Next, the structure of the light emitting element formation regions 15 will be described.

As shown in FIG. 2, a square light emitting element formation region 15 is formed on the upper side of each of the pixels 13. As shown in FIG. 5, an anode 20 is formed as a transparent electrode on the upper side of the second interlayer insulation film IL2 in the light emitting element formation region 15.

The anode 20 is a transparent conductive film having optical transmissivity, such as an ITO film, one end of which goes through the second interlayer insulation film IL2 and is electrically connected to the second drain region D2, as shown in FIG. 4. The top side 20 a of this anode 20 is made lyophilic to lower layer droplets 25D (see FIG. 9) by a lyophilic treatment (discussed below; step 12 in FIG. 6).

A third interlayer insulation film IL3, such as a silicon oxide film that insulates the anode 20 from other anodes 20, is deposited on the upper side of the anode 20. A square through-hole 21 made in the approximate middle on the upper side of the anode 20 is formed in this third interlayer insulation film IL3, and a barrier layer 22 is formed on the upper side of this third interlayer insulation film IL3.

The barrier layer 22 is formed from what is called a positive photosensitive material, which when exposed to exposure light Lpr (see FIG. 7) of a specific wavelength, only the exposed portion becomes soluble in a developing solution such as an alkaline solution, and more specifically is formed from a resin such as a photosensitive polyimide that repels a lower layer formation solution 25L (see FIG. 9) and an upper layer formation solution 27L (see FIG. 10), which are discussed below.

A receptacle hole 23 that flares out upward is formed across from the through-hole 21. The receptacle hole 23 is formed large enough that the lower layer droplet 25D (see FIG. 9) and upper layer droplet 27D (see FIG. 10), which are discussed below, can be accommodated in the corresponding light emitting element formation region 15. A barrier 24 that surrounds the light emitting element formation region 15 (the anode 20 and the through-hole 21) is formed by the inner peripheral surface of this receptacle hole 23.

A lower thin film layer (hole transport layer) 25 is formed as a lower layer pattern on the upper side of the anode 20 within the light emitting element formation region 15. The hole transport layer 25 is a pattern composed of a hole transport layer formation material 25 s (see FIG. 9) that constitutes a thin film layer formation material and a pattern formation material.

The hole transport layer formation material 25 s in this embodiment is, for example, a benzidine derivative, styrylamine derivative, triphenylmethane derivative, triphenylamine derivative, hydrazone derivative, or other such low-molecular weight compound, or a high-molecular weight compound whose structure partly includes one of these, or polyaniline, polythiophene, polyvinylcarbazole, α-naphthylphenyldiamine, a mixture of poly(3,4-ethylenedioxythiophene) and polystyrenesulfonic acid (PEDOT/PSS) (Baytron P, trademark of Bayer), or another such high-molecular weight compound.

This hole transport layer 25 contains a surfactant 26. The surfactant 26 has a lower layer functional group 26 a that is lyophilic (hydrophilic in this embodiment) with respect to the lower layer droplet 25D discussed below, and an upper layer functional group 26 b that is lyophilic (lipophilic in this embodiment) with respect to the upper layer droplets 27D discussed below. The surfactant 26 is contained such that its lower layer functional groups 26 a are on the hole transport layer 25 side, and its upper layer functional groups 26 b are exposed on the top side of the hole transport layer 25.

The lower layer functional group 26 a enhances affinity with the hydrophilic lower layer solvent discussed below (or with the hole transport layer formation material 25 s). This affinity is the result of the formation of a bond, such as a hydrogen bond, a coordination bond, an ion bond, or a covalent bond, or of an affinity force such as electrostatic attraction or van der Wall's force. Examples of the lower layer functional group 26 a include a hydroxyl group, oxalic acid group, ammonium group, sulfuric acid group, and phosphoric acid group, and sodium and potassium salts of these.

Meanwhile, the upper layer functional group 26 b enhances affinity with the hydrophobic upper layer solvent discussed below (or with a light emitting layer formation material 27 s). Examples of this upper layer functional group 26 b include a phenyl group, benzyl group, phenethyl group, hydroxyphenyl group, chlorophenyl group, aminophenyl group, naphthyl group, anthrenyl group, pyrenyl group, thienyl group, pyrrolyl group, cyclohexyl group, cyclohexenyl group, cyclopentyl group, cyclopentenyl group, pyridinyl group, and other such organic groups having a cyclic structure. Alternatively the upper layer functional group 26 b may TKTKbe a methyl group, ethyl group, propyl group, butyl group, pentyl group, hexyl group, heptyl group, octyl group, nonyl group, decyl group, tetradecyl group, hexadecyl group, octadecyl group, chloromethyl group, methoxyethyl group, hydroxyethyl group, aminoethyl group, cyano group, mercaptopropyl group, vinyl group, allyl group, acryloxyethyl group, methacryloxyethyl group, glycidoxypropyl group, acetoxy group, or other such organic group, and may be any organic group that enhances affinity with the upper layer solvent (or with the light emitting layer formation material 27 s).

An upper thin film layer (light emitting layer) 27 is laminated as an upper layer pattern on the upper side of the hole transport layer 25. The light emitting layer 27 is a pattern composed of the light emitting layer formation material 27 s (see FIG. 10) that constitutes a thin film layer formation material and a pattern formation material.

The light emitting layer 27 in this embodiment is formed from a light emitting layer formation material 27 s of the corresponding color (a red light emitting layer formation material that emits red light, a green light emitting layer formation material that emits green light, or a blue light emitting layer formation material that emits blue light). Examples of the red light emitting layer formation material include a high-molecular weight compound having an alkyl or alkoxy substituent on the benzene ring of a polyvinylenestyrene derivative, or a high-molecular weight compound having a cyano group on the vinylene group of a polyvinylenestyrene derivative. Examples of the green light emitting layer formation material include a polyvinylenestyrene derivative in which an alkyl, alkoxy, or allyl derivative substituent has been introduced into a benzene ring. Examples of the blue light emitting layer formation material include a polyfluorene derivative (such as a copolymer of dialkylfluorene and anthracene, or a copolymer of dialkylfluorene and thiophene).

An organic electroluminescence layer (organic EL layer) 30 is formed as a laminated pattern by the hole transport layer 25 and the light emitting layer 27.

A cathode 31 is formed as a back electrode composed of an optically reflective metal film, such as aluminum, on the upper side of the barrier layer 22 (barrier 24) and the upper side of the organic EL layer 30. The cathode 31 is formed so as to cover the entire surface of the element formation surface 11 a, and supplies potential for all of the light emitting element formation regions 15 shared by the pixels 13.

Specifically, an organic electroluminescence element (organic EL element) is constituted as a light emitting element by the anode 20, the organic EL layer 30, and the cathode 31.

When drive current corresponding to the data signal is supplied through the second drain region D2 to the anode 20, the organic EL layer 30 emits light at a brightness corresponding to this drive current. Here, the light emitted from the organic EL layer 30 toward the cathode 31 side (the upper side in FIG. 4) is reflected by the cathode 31. Accordingly, almost all of the light emitted from the organic EL layer 30 is transmitted through the anode 20, the second interlayer insulation film IL2, the first interlayer insulation film IL1, the gate insulation film Gox, the element formation surface 11 a, and the transparent substrate 11, and is emitted outward from the back (the display side 11 b) of the transparent substrate 11. Specifically, an image based on the data signal is displayed on the display side 11 b of the organic EL display 10.

An adhesive layer 32 composed of an epoxy resin or the like is formed on the upper side of the cathode 31, and a sealing substrate 16 that covers the element formation region 12 is applied via this adhesive layer 32. The sealing substrate 16 is a non-alkaline glass substrate, and serves to prevent the oxidation of the pixels 13, the wiring lines Lx, Ly, and Lv, and so forth.

Method for Manufacturing Organic EL Display 10

Next, the method for manufacturing the organic EL display 10 will be described. FIG. 6 is a flowchart illustrating the method for manufacturing the organic EL display 10, and FIGS. 7 to 10 are diagrams illustrating this method for manufacturing the organic EL display 10.

As shown in FIG. 6, first an organic EL layer preliminary step (step S11) is performed, in which the wiring lines Lx, Ly, Lv, and Lvc and the transistors T1 and T1 are formed on the element formation surface 11 a of the transparent substrate 11, and the barrier layer 22 is patterned. FIG. 7 is a diagram illustrating this organic EL layer preliminary step.

Specifically, in the organic EL layer preliminary step, first a crystallized polysilicon film is formed by excimer laser or the like over the entire element formation surface 11 a, and this polysilicon film is patterned to form the channel films B1 and B2. Next, the gate insulation film Gox composed of a silicon oxide film or the like is formed over the entire upper surface of the element formation surface 11 a and the channel films B1 and B2, and a low-resistance metal film of tantalum or the like is deposited over the entire upper surface of the gate insulation film Gox. This low-resistance metal film is patterned to form the gate electrodes G1 and G2, the lower electrode Cp1 of the holding capacitor Cs, and the scanning line Lx.

When the gate electrodes G1 and G2 have been formed, an n-type impurity region is formed in each of the channel films B1 and B2 by ion doping, using the gate electrodes G1 and G2 as masks. This forms the channel regions C1 and C2, the source regions S1 and S2, and the drain regions D1 and D2. When the source regions S1 and S2 and the drain regions D1 and D2 have been formed in the channel films B1 and B2, respectively, the first interlayer insulation film IL1 composed of a silicon oxide film or the like is deposited over the entire upper surface of the gate electrodes G1 and G2, the scanning line Lx, and the gate insulation film Gox.

When the first interlayer insulation film IL1 has been formed, a pair of contact holes is patterned at positions relative to the source regions S1 and S2 and the drain regions D1 and D2 in the first interlayer insulation film IL1. Next, a metal film of aluminum or the like is deposited over the entire upper surface of the first interlayer insulation film IL1 and in these contact holes, and this metal film is patterned to form the data line Ly and the upper electrode Cp2 of the holding capacitor Cs corresponding to each of the source regions S1 and S2. At the same time, the drain electrodes Dp1 and Dp2 corresponding to the drain regions D1 and D2 are formed. The second interlayer insulation film IL2 composed of a silicon oxide film or the like is deposited over the entire upper surface of the data line Ly, the upper electrode Cp2, the drain regions D1 and D2, and the first interlayer insulation film IL1. This forms the switching transistor T1 and the drive transistor T2.

When the second interlayer insulation film IL2 has been deposited, a via hole is formed at a position across from the second drain region D2 in this second interlayer insulation film IL2. Then, a transparent conductive film having optical transmissivity, such as an ITO film, is deposited over the entire upper surface of the second interlayer insulation film IL2 and in this via hole, and this transparent conductive film is patterned to form the anode 20 that connects to the second drain region D2. When the anode 20 has been formed, the third interlayer insulation film IL3 composed of a silicon oxide film or the like is formed over the entire upper surface of the second interlayer insulation film IL2 and this anode 20.

When the third interlayer insulation film IL3 has been deposited, as shown in FIG. 7, the entire upper surface of the third interlayer insulation film IL3 is coated with a photosensitive polyimide resin or the like to form the barrier layer 22. Developing is then performed by exposing the barrier layer 22 at a position across from the anode 20 to exposure light Lpr of a specific wavelength through a mask Mk, which results in the patterning of the receptacle hole 23, whose inner peripheral surface is the barrier 24, in this barrier layer 22.

When the receptacle hole 23 has been patterned, the third interlayer insulation film IL3 is patterned using the barrier layer 22 as a mask, and a through-hole 21 that communicates with the receptacle hole 23 is formed on the upper side of the anode 20.

This completes the organic EL layer preliminary step in which the wiring lines Lx, Ly, Lv, and Lvc and the transistors T1 and T2 are formed on the element formation surface 11 a, and the receptacle hole 23 is patterned.

As shown in FIG. 6, when the organic EL layer preliminary step is complete (step S11), a surface treatment step, in which the inside of the receptacle hole 23 and the surface of the barrier layer 22 are treated, is performed in order to form the lower layer droplet 25D and the upper layer droplet 27D discussed below (step S12). FIG. 8 is a diagram illustrating this surface treatment step.

Specifically, in the surface treatment step, first the entire element formation surface 11 a is exposed to an oxygen-based plasma Ps to perform a hydrophilic treatment in which the third interlayer insulation film IL3 (through-hole 21) and the anode 20 (top side 20 a) in the receptacle hole 23 are rendered hydrophilic. When this hydrophilic treatment has been performed, the entire element formation surface 11 a is exposed to a fluorine-based plasma Ps to perform a liquid repellency treatment in which the barrier layer 22 (barrier 24) is once again rendered liquid repellent.

As shown in FIG. 6, when the surface treatment step is complete (step S12), a lower layer formation step (step S13) is performed, in which a lower layer droplet 25D containing the surfactant 26 and the hole transport layer formation material 25 s is formed inside the receptacle hole 23, and the hole transport layer 25 is formed. FIG. 9 is a diagram illustrating this lower layer formation step.

First, the structure of the droplet discharge apparatus used to form the lower layer droplet 25D will be described.

As shown in FIG. 9, a liquid discharge head 35 that constitutes the droplet discharge apparatus in this embodiment is equipped with a nozzle plate 36. Numerous nozzles 36 n for discharging a liquid are formed facing upward on the bottom side (the nozzle formation side 36 a) of this nozzle plate 36. A liquid supply chamber 37 that communicates with a liquid reservoir (not shown) and allows a liquid to be supplied to the nozzles 36 n is formed on the upper side of the nozzles 36 n. A diaphragm 38 that vibrates reciprocally up and down and expands and contracts the volume inside the liquid supply chamber 37 is provided on the upper side of the liquid supply chamber 37. A piezoelectric element 39 that vibrates the diaphragm 38 by expanding and contracting vertically is provided on the upper side of each diaphragm 38 at a position across from the liquid supply chamber 37.

As shown in FIG. 9, a transparent substrate 11 conveyed to the droplet discharge apparatus is positioned with its element formation surface 11 a parallel to the nozzle formation side 36 a and with the center of the receptacle holes 23 disposed directly under each of the nozzles 36 n.

Here, a lower layer formation solution 25L produced by dissolving the hole transport layer formation material 25 s in a lower layer solvent and mixing the surfactant 26 into this solution is supplied into the liquid supply chamber 37.

The lower layer solvent in this embodiment is a hydrophilic liquid, whose main component includes water, ethanol, N-methylpyrrolidone, 1,3-dimethyl-2-imidazolidinone or another such polar liquid. Accordingly, the surfactant 26 mixed into the lower layer formation solution 25L is uniformly dissolved by the lower layer functional group 26 a thereof, without clumping within the lower layer formation solution 25L. In other words, the lower layer formation solution 25L is a hydrophilic solution in which the surfactant 26 has been uniformly mixed.

When a drive signal for forming the lower layer droplet 25D is inputted to the liquid discharge head 35, the piezoelectric element 39 expands or contracts according to this drive signal, thereby increasing or decreasing the volume of the liquid supply chamber 37. If the volume of the liquid supply chamber 37 decreases here, the lower layer formation solution 25L is discharged as a microscopic lower layer droplet 25 b from the nozzle 36 n in an amount corresponding to the reduction in volume. The discharged microscopic lower layer droplet 25 b lands on the top side of the anode 20 in the receptacle hole 23. When the volume of the liquid supply chamber 37 then increases, the lower layer formation solution 25L is supplied from a liquid reservoir (not shown) into the liquid supply chamber 37 in an amount equal to the increase in volume. In other words, the liquid discharge head 35 discharges the required volume of lower layer formation solution 25L toward the receptacle hole 23 by means of the expansion and contraction of the liquid supply chamber 37. Here, the liquid discharge head 35 discharges the microscopic lower layer droplet 25 b in an amount such that the hole transport layer formation material 25 s contained in the lower layer droplet 25D will form a film of the desired thickness.

The microscopic lower layer droplet 25 b discharged into the receptacle hole 23 uniformly wets and spreads out over the entire top side of the anode 20 and inside the through-hole 21 in an amount corresponding to how much the above-mentioned hydrophilic treatment has been performed. After a while, the uniformly spread-out microscopic lower layer droplets 25 b form the lower layer droplet 25D, which has a hemispherical surface, by means of the liquid repellency of the barrier 24 and its own surface tension, as shown by the two-dot chain line in FIG. 9.

When the lower layer droplet 25D has been formed, the transparent substrate 11 (the lower layer droplet 25D) is placed under a specific reduced pressure to evaporate the lower layer solvent of the lower layer droplet 25D and solidify the hole transport layer formation material 25 s in a state in which it uniformly contains the surfactant 26. The solidified hole transport layer formation material 25 s forms the hole transport layer 25 in a uniform shape, according to the amount of uniform spreading over the entire top side of the anode 20.

The lower layer droplet 25D here is dried so that the upper layer functional groups 26 b, which are not lyophilic to the lower layer solvent, will be exposed on the surface of the surface of the lower layer droplet 25D. Accordingly, the hole transport layer 25 has the surfactant 26 disposed such that the lower layer functional groups 26 a are inward, and the upper layer functional groups 26 b on exposed.

This forms the hole transport layer 25 containing the surfactant 26 over the entire top side of the anode 20 in the through-hole 21 (the receptacle hole 23).

As shown in FIG. 6, when the hole transport layer 25 has been formed (step S13), an upper layer formation step (step S14) is performed in which the upper layer droplet 27D containing a light emitting layer formation material of the corresponding color is formed in the receptacle hole 23, and the light emitting layer 27 is formed. FIG. 10 is a diagram illustrating the upper layer formation step.

In this upper layer formation step, just as in the lower layer formation step, a microscopic upper layer droplet 27 b, composed of the upper layer formation solution 27L obtained by dissolving a light emitting layer formation material 27 s of one color in an upper layer solvent, is discharged from a nozzle 36 n onto the corresponding hole transport layer 25. The liquid discharge head 35 here discharges the microscopic upper layer droplet 27 b in an amount corresponding to the desired film thickness in which the light emitting layer 27 is to be formed in the receptacle hole 23.

The upper layer solvent in this embodiment is a hydrophobic liquid that will not dissolve the hole transport layer formation material 25 s. The main component of this upper layer solvent is a non-polar liquid such as benzene, toluene, xylene, cyclohexylbenzene, dihydrobenzofuran, trimethylbenzene, or tetramethylbenzene. In other words, the upper layer formation solution 27L is a hydrophobic solution that repulses the lower layer formation solution 25L.

The hydrophobic microscopic upper layer droplet 27 b discharged over the hole transport layer 25 uniformly wets and spreads out over the entire top side of the hole transport layer 25 in an amount corresponding to how much surfactant 26 is contained. After a while, the uniformly spread-out hydrophobic microscopic upper layer droplet 27 b forms the upper layer droplet 27D, which has a hemispherical surface, by means of the liquid repellency of the barrier 24 and its own surface tension, as shown by the two-dot chain line in FIG. 10.

When the upper layer droplet 27D has been formed, just as in the lower layer formation step described above, the transparent substrate 11 (upper layer droplet 27D) is placed under a specific reduced pressure to evaporate the upper layer solvent and solidify the light emitting layer formation material 27 s. The solidified light emitting layer formation material 27 s forms the light emitting layer 27 in a uniform shape (such as the film thickness distribution within the light emitting element formation region 15 or the film thickness distribution between light emitting element formation regions 15), according to the amount of uniform wetting and spreading over the entire top side of the hole transport layer 25. Specifically, this forms the organic EL layer 30 having a uniform shape.

As shown in FIG. 6, when the upper layer formation step is complete (step S14), an organic EL layer post-step (step S15) is performed, in which the cathode 31 is formed over the light emitting layer 27 (organic EL layer 30) and the barrier layer 22, and the pixel 13 is sealed. Specifically, the cathode 31 composed of a metal film such as aluminum is deposited over the entire top side of the organic EL layer 30 and the barrier layer 22, forming an organic EL element composed of the anode 20, the organic EL layer 30, and the cathode 31. When the organic EL element has been formed, an adhesive layer 32 is formed by coating the entire top side of the cathode 31 (pixel 13) with an epoxy resin or the like, and the sealing substrate 16 is applied to the transparent substrate 11 via this adhesive layer 32.

The result of the above is that an organic EL display 10 in which the organic EL layer 30 has a uniform shape can be manufactured.

Next, the effects of this embodiment, constituted as above, will be described.

(1) With the above embodiment, the lower layer formation solution 25L was produced by mixing the surfactant 26, which contained the lower layer functional group 26 a and the upper layer functional group 26 b, into the lower layer solvent, and the lower layer droplet 25D composed of this lower layer formation solution 25L was dried to form the hole transport layer 25. Therefore, the upper layer droplet 27D can wet and spread out over the entire top side of the hole transport layer 25 in an amount corresponding to how much surfactant 26 (upper layer functional groups 26 b) is contained.

(2) Furthermore, the lower layer functional groups 26 a allow the surfactant 26 to be uniformly mixed into the lower layer formation solution 25L, and allow the surfactant 26 to be contained uniformly in the hole transport layer 25. As a result, damage to the hole transport layer 25 by surface treatment with a plasma or the like can be avoided, and the shape of the light emitting layer 27 can be made uniform. This in turn allows the amount of surface treatment to which the hole transport layer 25 is subjected to be reduced, which affords a more uniform shape of the organic EL layer 30 and increases the productivity of the organic EL display 10.

(3) With the above embodiment, just the top side of the hole transport layer 25 was rendered hydrophilic by the surfactant 26 contained in the hole transport layer 25. Therefore, the surface state (liquid repellency) of the barrier layer 22 and so forth can be maintained better than when the entire surface is treated with plasma or the like. As a result, wetting of the discharged microscopic upper layer droplets 27 b and so forth in the receptacle holes 23 can be avoided, making it possible to reliably form the light emitting layer 27 in an amount relative to the amount of this microscopic upper layer droplet 27 b. This in turn affords a further increase in the shape uniformity between organic EL layers 30.

(4) With the above embodiment, the upper layer solvent of the upper layer formation solution 27L was a hydrophobic (non-polar) liquid, and was a liquid that did not dissolve the hole transport layer formation material 25 s. Therefore, the upper layer droplet 27D can be formed while maintaining the shape of the hole transport layer 25. As a result, the shape of the light emitting layer 27, and in turn the shape of the organic EL layer 30, can be made more uniform according to how well the uniformity of the hole transport layer 25 is maintained.

(5) With the above embodiment, the lower layer droplets 25D were formed by the microscopic lower layer droplets 25 b discharged from a droplet discharge apparatus. Therefore, the desired volume of the surfactant 26 can be reliably contained in the lower layer droplets 25D (hole transport layers 25), and the organic EL layers 30 can be formed more uniformly than with other liquid phase processes (such as spin coating).

The above embodiment may be modified as follows.

Examples of the surfactant 26 in the above embodiment include pentaethylene glycol monobenzyl ether, 4-n-pentylcyclohexanoic acid, 4-phenoxy-butyric acid, 2-phenoxyethanol, 1-phenoxy-2-propanol, 2-phenoxypropanol, 2-phenoxypropionic acid, 3-phenoxypropionic acid, 5-phenoxyvaleric acid, phenylaniline, phenylalaniol, 4-phenyl-1-butanol, 4-phenyl-2-butanol, 3-phenoxy-1,2-propanediol, 2-phenylbutyricacid, 4-phenylbutyricacid, 1,2-phenylenediacetic acid, 1,3-phenylenediacetic acid, N-phenyldiethanolamine, 2-phenyl ethyl alcohol, 2-phenylethylamine, N-phenylethyleneamine, phenyl ethylene glycol, 2-phenylglycine, N-phenylglycine, 2-phenyl glycol, 6-phenylhexanoic acid, 3-phenylacetic acid, 5-phenyl-1-pentanol, 5-phenylpentanoic acid, 5-phenyl-4-pentyn-1-ol, 2-phenyl-1,3-propanediol, 3-phenyl-1-propanol, 3-phenylpropionaldehyde, 2-phenylpropionic acid, 3-phenylpropylamine, 4-(3-phenylpropyl)pyridine, 1-phenyl-1-propyn-3-ol, (phenylthio)acetic acid, 2-(phenylthio)ethanol, 5-phenylvaleric acid, 1-naphthyloxyacetic acid, 2-naphthyloxyacetic acid, 2-(1-naphthyl)ethanol, 1-(1-naphthyl)ethanol, 1-(1-naphthyl)ethylamine, N-1-naphthylethylenediamine, 3-(2-naphthyl)alanine, 1-naphthalenic acid, 2-naphthalenic acid, 1-naphthalenesulfonic acid, 2-naphthalenesulfonic acid, 2-naphthaleneacetic acid, 1-anthracenecarboxylic acid, 2-anthracenecarboxylic acid, 3-anthracenecarboxylic acid, 1-pyrenebutyric acid, 1-pyrenemethanol, 2-pyridinemethanol, 3-pyridinemethanol, 4-pyridinemethanol, 2-pyridinepropanol, 3-pyridinepropanol, 4-pyridinepropanol, 2-pyridineacetic acid, 3-pyridineacetic acid, 4-pyridineacetic acid, 3-(3-pyridyl)acrylic acid, 2-(2-pyridyl)ethanesulfonic acid, 2-(4-pyridyl)ethanesulfonic acid, (4-pyridylthio)acetic acid, thiophene-2-acetic acid, thiophene-3-acetic acid, 2-thiopheneacrylic acid, 2-thiophene ethanol, 3-thiophene ethanol, 3-thiophene malonic acid, 2-thiophene methanol, 3-thiophene methanol, n-decyltrimethylammonium chloride, n-decyltrimethylammonium bromide, n-dodecyltrimethylammonium chloride, n-dodecyltrimethylammonium bromide, n-hexadecyltrimethylammonium chloride, n-hexadecyltrimethylammonium bromide, n-octadecyltrimethylammonium chloride, n-octadecyltrimethylammonium bromide, di-n-dodecyldimethylammonium chloride, di-n-dodecyldimethylammonium bromide, n-decylpyridinium chloride, n-decylpyridinium bromide, n-dodecylpyridinium chloride, n-dodecylpyridinium bromide, n-dodecylpyridinium iodide, n-tetradecylpyridinium chloride, n-tetradecylpyridinium bromide, n-hexadecylpyridinium chloride, n-hexadecylpyridinium bromide, n-hexadecylpyridinium iodide, n-octadecylpyridinium chloride, n-octadecylpyridinium bromide, n-dodecylpicolinium chloride, n-dodecylpicolinium bromide, n-octadecylpicolinium chloride, n-octadecylpicolinium bromide, n-octadecylpicolinium iodide, N,N′-dimethyl-4,4′-bipyridinium dichloride, N,N′-dimethyl-4,4′-bipyridinium dibromide, N,N′-dimethyl-4,4′-bipyridinium bis(methylsulfate), N,N′-dimethyl-4,4′-bipyridinium bis(p-toluenesulfonate), N,N′-di(n-propyl)-4,4′-bipyridinium dichloride, N,N′-di(n-propyl)-4,4′-bipyridinium dibromide, N,N′-di(n-propyl)-4,4′-bipyridinium bis(p-toluenesulfonate), N,N′-dibenzyl-4,4′-bipyridinium dichloride, N,N′-dibenzyl-4,4′-bipyridinium dibromide, N,N′-dibenzyl-4,4′-bipyridinium diiodide, N,N′-dibenzyl-4,4′-bipyridinium bis(p-toluenesulfonate), N,N′-diphenyl-4,4′-bipyridinium dichloride, N,N′-diphenyl-4,4′-bipyridinium dibromide, N,N′-bis(3-sulfonate propyl)-4,4′-bipyridinium, 1,3-bis{N-(N′-methyl-4,4′-bipyridyl)}propane tetrachloride, 1,3-bis{N-(N′-methyl-4,4′-bipyridyl)}propane tetrabromide, 1,3-bis{N-(N′-benzyl-4,4′-bipyridyl)}propane tetrachloride, 1,3-bis{N-(N′-benzyl-4,4′-bipyridyl)}propane tetrabromide, 1,4-bis{N-(N′-methyl-4,4′-bipyridyl)}butane tetrachloride, 1,4-bis{N-(N′-methyl-4,4′-bipyridyl)}butane tetrabromide, 1,4-bis{N-(N′-benzyl-4,4′-bipyridyl)}butane tetrachloride, 1,4-bis{N-(N′-benzyl-4,4′-bipyridyl)}butane tetrabromide, α,α′-bis{N-(N′-methyl-4,4′-bipyridyl)}-o-xylene tetrachloride, α,α′-bis{N-(N′-methyl-4,4′-bipyridyl)}-o-xylene tetrabromide, α,α′-bis{N-(N′-benzyl-4,4′-bipyridyl)}-o-xylene tetrachloride, α,α′-bis{N-(N′-benzyl-4,4′-bipyridyl)}-o-xylene tetrabromide, α,α′-bis{N-(N′-methyl-4,4′-bipyridyl)}-m-xylene tetrachloride, α,α′-bis{N-(N′-methyl-4,4′-bipyridyl)}-m-xylene tetrabromide, α,α′-bis{N-(N′-benzyl-4,4′-bipyridyl)}-m-xylene tetrachloride, α,α′-bis{N-(N′-benzyl-4,4′-bipyridyl)}-m-xylene tetrabromide, α,α′-bis{N-(N′-methyl-4,4′-bipyridyl)}-p-xylene tetrachloride, α,α′-bis{N-(N′-methyl-4,4′-bipyridyl)}-p-xylene tetrabromide, α,α′-bis{N-(N′-benzyl-4,4′-bipyridyl)}-p-xylene tetrachloride, α,α′-bis{N-(N′-benzyl-4,4′-bipyridyl)}-p-xylene tetrabromide, N-n-dodecyl-N′-methyl-4,4′-bipyridinium dichloride, N-n-dodecyl-N′-methyl-4,4′-bipyridinium bromide iodide, N-n-dodecyl-N′-methyl-4,4′-bipyridinium bromide methyl sulfate, N-n-dodecyl-N′-benzyl-4,4′-bipyridinium dichloride, N-n-dodecyl-N′-benzyl-4,4′-bipyridinium dibromide, N-n-dodecyl-N′-benzyl-4,4′-bipyridinium chloride bromide, N-n-hexadecyl-N′-methyl-4,4′-bipyridinium dichloride, N-n-hexadecyl-N′-methyl-4,4′-bipyridinium bromide iodide, N-n-hexadecyl-N′-methyl-4,4′-bipyridinium bromide methyl sulfate, N-n-hexadecyl-N′-benzyl-4,4′-bipyridinium dichloride, N-n-hexadecyl-N′-benzyl-4,4′-bipyridinium dibromide, N-n-octadecyl-N′-methyl-4,4′-bipyridinium dichloride, N-n-octadecyl-N′-methyl-4,4′-bipyridinium bromide iodide, N-n-octadecyl-N′-methyl-4,4′-bipyridinium bromide methyl sulfate, N-n-octadecyl-N′-benzyl-4,4′-bipyridinium dibromide, N,N′-di-n-dodecyl-4,4′-bipyridinium dichloride, N,N′-di-n-dodecyl-4,4′-bipyridinium dibromide, N,N′-di-n-hexadecyl-4,4′-bipyridinium dichloride, N,N′-di-n-hexadecyl-4,4′-bipyridinium dibromide, 1,3-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}propane tetrachloride, 1,3-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}propane tetrabromide, 1,4-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}butane tetrabromide, 1,6-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}hexane tetrabromide, 1,3-bis{N-(N′-n-hexadecyl-4,4′-bipyridyl)}propane tetrabromide, 1,4-bis{N-(N′-n-hexadecyl-4,4′-bipyridyl)}butane tetrabromide, 1,6-bis{N-(N′-n-hexadecyl-4,4′-bipyridyl)}hexane tetrabromide, α,α′-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}-o-xylene tetrachloride, α,α′-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}-o-xylene tetrabromide, α,α′-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}-m-xylene tetrachloride, α,α′-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}-m-xylene tetrabromide, α,α′-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}-p-xylene tetrachloride, α,α′-bis{N-(N′-n-dodecyl-4,4′-bipyridyl)}-p-xylene tetrabromide, α,α′-bis{N-(N′-n-hexadecyl-4,4′-bipyridyl)}-o-xylene tetrachloride, α,α′-bis{N-(N′-n-hexadecyl-4,4′-bipyridyl)}-o-xylene tetrabromide, α,α′-bis{N-(N′-n-hexadecyl-4,4′-bipyridyl)}-m-xylene tetrachloride, α,α′-bis{N-(N′-n-hexadecyl-4,4′-bipyridyl)}-m-xylene tetrabromide, α,α′-bis{N-(N′-n-hexadecyl-4,4′-bipyridyl)}-p-xylene tetrachloride, α,α′-bis{N-(N′-n-hexadecyl-4,4′-bipyridyl)}-p-xylene tetrabromide, cyclohexyl acrylate, cyclohexyl methacrylate, cyclohexylacrylamide, cyclohexylmethacrylamide, N-cyclohexyl-N-methylacrylamide, N-cyclohexyl-N-methylmethacrylamide, cyclohexylmethyl acrylate, cyclohexylmethyl methacrylate, cyclohexylmethylacrylamide, cyclohexylmethylmethacrylamide, N-cyclohexylmethyl-N-methylacrylamide, N-cyclohexylmethyl-N-methylmethacrylamide, phenyl acrylate, phenyl methacrylate, phenyl acrylamide, phenylmethacrylamide, N-methyl-N-phenylacrylamide, N-methyl-N-phenylmethacrylamide, benzyl acrylate, benzyl methacrylate, benzylacrylamide, benzylmethacrylamide, N-benzyl-N-methylacrylamide, N-benzyl-N-methylmethacrylamide, 1-norbornyl acrylate, 1-norbornyl methacrylate, 1-norbornylacrylamide, 1-norbornyl methacrylamide, N-methyl-N-(1-norbornyl) acrylamide, N-methyl-N-(1-norbornyl)methacrylamide, cyclooctyl acrylate, cyclooctyl methacrylate, cyclooctylacrylamide, cyclooctylmethacrylamide, N-cyclooctyl-N-methylacrylamide, N-cyclooctyl-N-methylmethacrylamide, adamantyl acrylate, adamantyl methacrylate, adamantylacrylamide, adamantylmethacrylamide, N-adamantyl-N-methylacrylamide, N-adamantyl-N-methylmethacrylamide, 1-naphthyl acrylate, 1-naphthyl methacrylate, 1-naphthylacrylamide, 1-naphthylmethacrylamide, N-methyl-N-(1-naphthyl)acrylamide, N-methyl-N-(1-naphthyl)methacrylamide, 2-naphthyl acrylate, 2-naphthyl methacrylate, 2-naphthylacrylamide, 2-naphthylmethacrylamide, N-methyl-N-(2-naphthyl)acrylamide, N-methyl-N-(2-naphthyl)methacrylamide, n-dodecyl acrylate, n-dodecyl methacrylate, n-dodecylacrylamide, n-dodecylmethacrylamide, N-n-dodecyl-N-methylacrylamide, N-n-dodecyl-N-methylmethacrylamide, cyclododecyl acrylate, cyclododecyl methacrylate, cyclododecylacrylamide, cyclododecylmethacrylamide, N-cyclododecyl-N-methylacrylamide, N-cyclododecyl-N-methylmethacrylamide, n-hexadecyl acrylate, n-hexadecyl methacrylate, n-hexadecylacrylamide, n-hexadecylmethacrylamide, N-n-hexadecyl-N-methylacrylamide, N-n-hexadecyl-N-methylmethacrylamide, n-octadecyl acrylate, n-octadecyl methacrylate, n-octadecylacrylamide, n-octadecylmethacrylamide, N-n-octadecyl-N-methylacrylamide, N-n-octadecyl-N-methylmethacrylamide, di-n-octylacrylamide, di-n-octylmethacrylamide, di-n-decylacrylamide, di-n-decylmethacrylamide, di-n-dodecylacrylamide, di-n-dodecylmethacrylamide, 9-anthracene methyl acrylate, 9-anthracene methyl methacrylate, 9-anthracenemethylacrylamide, 9-anthracenemethylmethacrylamide, 9-phenanthrene methyl acrylate, 9-phenanthrene methyl methacrylate, 9-phenanthrenemethylacrylamide, 9-phenanthrenemethylmethacrylamide, N-methyl-N-(9-phenanthrenemethyl)acrylamide, N-methyl-N-(9-phenanthrenemethyl)methacrylamide, 1-pyrene methyl acrylate, 1-pyrene methyl methacrylate, 1-pyrenemethylacrylamide, 1-pyrenemethylmethacrylamide, N-methyl-N-(1-pyrenemethyl)acrylamide, N-methyl-N-(1-pyrenemethyl)methacrylamide, and 4-acryloyloxymethylphthalocyanine.

In the above embodiment, the surfactant 26 having the lower layer functional group 26 a and the upper layer functional group 26 b was mixed into the lower layer formation solution 25L, but the invention is not limited to this, and a silane coupling agent having the upper layer functional group 26 b may be mixed into the lower layer formation solution 25L, so that a silane coupling agent or a hydrolyzate of such silane coupling agent is contained in the hole transport layer 25. Examples of this silane coupling agent include dimethyldimethoxysilane, diethyldiethoxysilane, 1-propenylmethyldichlorosilane, propyldimethylchlorosilane, propylmethyldichlorosilane, propyltrichlorosilane, propyltriethoxysilane, propyltrimethoxysilane, styrylethyltrimethoxysilane, tetradecyltrichlorosilane, 3-thiocyanatopropyltriethoxysilane, p-tolyldimethylchlorosilane, p-tolylmethyldichlorosilane, p-tolyltrichlorosilane, p-tolyltrimethoxysilane, p-tolyltriethoxysilane, di-n-propyldi-n-propoxysilane, diisopropyldiisopropoxysilane, di-n-butyldi-n-butyloxysilane, di-sec-butyldi-sec-butyloxysilane, di-t-butyldi-t-butyloxysilane, octadecyltrichlorosilane, octadecylmethyldiethoxysilane, octadecyltriethoxysilane, octadecyltrimethoxysilane, octadecyldimethylchlorosilane, octadecylmethyldichlorosilane, octadecylmethoxydichlorosilane, 7-octenyldimethylchlorosilane, 7-octenyltrichlorosilane, 7-octenyltrimethoxysilane, octylmethyldichlorosilane, octyldimethylchlorosilane, octyltrichlorosilane, 10-undecenyldimethylchlorosilane, undecyltrichlorosilane, vinyldimethylchlorosilane, methyloctadecyldimethoxysilane, methyldodecyldiethoxysilane, methyloctadecyldimethoxysilane, methyloctadecyldiethoxysilane, n-octylmethyldimethoxysilane, n-octylmethyldiethoxysilane, triacontyldimethylchlorosilane, triacontyltrichlorosilane, methyltrimethoxysilane, methyltriethoxysilane, methyltri-n-propoxysilane, methylisopropoxysilane, methyl-n-butyloxysilane, methyltri-sec-butyloxysilane, methyltri-t-butyloxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, ethyltri-n-propoxysilane, ethylisopropoxysilane, ethyl-n-butyloxysilane, ethyltri-sec-butyloxysilane, ethyltri-t-butyloxysilane, n-propyltrimethoxysilane, isobutyltrimethoxysilane, n-hexyltrimethoxysilane, hexadecyltrimethoxysilane, n-octyltrimethoxysilane, n-dodecyltrimethoxysilane, n-octadecyltrimethoxysilane, n-propyltriethoxysilane, isobutyltriethoxysilane, n-hexyltriethoxysilane, hexadecyltriethoxysilane, n-octyltriethoxysilane, n-dodecyltrimethoxysilane, n-octadecyltriethoxysilane, 2-[2-(trichlorosilyl)ethyl]pyridine, 4-[2-(trichlorosilyl)ethyl]pyridine, diphenyldimethoxysilane, diphenyldiethoxysilane, 1,3-(trichlorosilylmethyl)heptacosane, dibenzyldimethoxysilane, dibenzyldiethoxysilane, phenyltrimethoxysilane, phenylmethyldimethoxysilane, phenyldimethylmethoxysilane, phenyldimethoxysilane, phenyldiethoxysilane, phenylmethyldiethoxysilane, phenyldimethylethoxysilane, benzyltriethoxysilane, benzyltrimethoxysilane, benzylmethyldimethoxysilane, benzyldimethylmethoxysilane, benzyldimethoxysilane, benzyldiethoxysilane, benzylmethyldiethoxysilane, benzyldimethylethoxysilane, benzyltriethoxysilane, dibenzyldimethoxysilane, dibenzyldiethoxysilane, 3-acetoxypropyltrimethoxysilane, 3-acryloxypropyltrimethoxysilane, allyltrimethoxysilane, allyltriethoxysilane, 4-aminobutyltriethoxysilane, (aminoethylaminomethyl)phenethyltrimethoxysilane, N-(2-aminoethyl)-3-aminopropylmethyldimethoxysilane, N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, 6-(aminohexylaminopropyl)trimethoxysilane, p-aminophenyltrimethoxysilane, p-aminophenylethoxysilane, m-aminophenyltrimethoxysilane, m-aminophenylethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, ω-aminoundecyltrimethoxysilane, amyltriethoxysilane, benzooxasilepin dimethyl ester, 5-(bicycloheptenyl)triethoxysilane, bis(2-hydroxyethyl)-3-aminopropyltriethoxysilane, 8-bromooctyltrimethoxysilane, bromophenyltrimethoxysilane, 3-bromopropyltrimethoxysilane, n-butyltrimethoxysilane, 2-chloromethyltriethoxysilane, chloromethylmethyldiethoxysilane, chloromethylmethyldiisopropoxysilane, p-(chloromethyl)phneyltrimethoxysilane, chloromethyltriethoxysilane, chlorophenyltriethoxysilane, 3-chloropropylmethyldimethoxysilane, 3-chloropropyltriethoxysilane, 3-chloropropyltrimethoxysilane, 2-(4-chlorosulfonylphenyl)ethyltrimethoxysilane, 2-cyanoethyltriethoxysilane, 2-cyanoethyltrimethoxysilane, cyanomethylphenethyltriethoxysilane, 3-cyanopropyltriethoxysilane, 2-(3-cyclohexenyl)ethyltrimethoxysilane, 2-(3-cyclohexenyl)ethyltriethoxysilane, 3-cyclohexenyl trichlorosilane, 2-(3-cyclohexenyl)ethyltrichlorosilane, 2-(3-cyclohexenyl)ethyldimethylchlorosilane, 2-(3-cyclohexenyl)ethylmethyldichlorosilane, cyclohexyldimethylchlorosilane, cyclohexylethyldimethoxysilane, cyclohexylmethyldichlorosilane, cyclohexylmethyldimethoxysilane, (cyclohexylmethyl)trichlorosilane, cyclohexyltrichlorosilane, cyclohexyltrimethoxysilane, cyclooctyltrichlorosilane, (4-cyclooctenyl)trichlorosilane, cyclopentyltrichlorosilane, cyclopentyltrimethoxysilane, 1,1-diethoxy-1-silacyclopenta-3-ene, 3-(2,4-dinitrophenylamino)propyltriethoxysilane, (dimethylchlorosilyl)methyl-7,7-dimethylnorpinane, (cyclohexylaminomethyl)methyldiethoxysilane, (3-cyclopentadienylpropyl)triethoxysilane, (N,N-diethyl-3-aminopropyl)trimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltriethoxysilane, (furfuryloxymethyl)triethoxysilane, 2-hydroxy-4-(3-triethoxypropoxy)diphenyl ketone, 3-(p-methoxyphenyl)propylmethyldichlorosilane, 3-(p-methoxyphenyl)propyltrichlorosilane, p-(methylphenethyl)methyldichlorosilane, p-(methylphenethyl)trichlorosilane, p-(methylphenethyl)dimethylchlorosilane, 3-morpholinopropyltrimethoxysilane, (3-glycidoxypropyl)methyldiethoxysilane, 3-glycidoxypropyltrimethoxysilane, 1,2,3,4,7,7-hexachloro-6-methyldiethoxysilyl-2-norbornene, 1,2,3,4,7,7-hexachloro-6-triethoxysilyl-2-norbornene, 3-iodopropyltrimethoxysilane, 3-isocyanatopropyltriethoxysilane, (mercaptomethyl)methyldiethoxysilane, 3-mercaptopropylmethyldimethoxysilane, 3-mercaptopropyldimethoxysilane, 3-mercaptopropyltriethoxysilane, 3-methacryloxypropylmethyldiethoxysilane, 3-methacryloxypropyltrimethoxysilane, methyl{2-(3-trimethoxysilylpropylamino)ethylamino}-3-propionate, 7-octenyltrimethoxysilane, R—N-α-phenethyl-N′-triethoxysilylpropylurea, S-N-α-phenethyl-N′-triethoxysilylpropylurea, phenethyltrimethoxysilane, phenethylmethyldimethoxysilane, phenethyldimethylmethoxysilane, phenethyldimethoxysilane, phenethyldiethoxysilane, phenethylmethyldiethoxysilane, phenethyldimethylethoxysilane, phenethyltriethoxysilane, (3-phenylpropyl)dimethylchlorosilane, (3-phenylpropyl)methyldichlorosilane, N-phenylaminopropyltrimethoxysilane, N-(triethoxysilylpropyl)dansylamide, N-(3-triethoxysilylpropyl)-4,5-dihydroimidazole, 2-(triethoxysilylethyl)-5-(chloroacetoxy)bicycloheptane, (S)-N-triethoxysilylpropyl-o-menthocarbamate, 3-(triethoxysilylpropyl)-p-nitrobenzamide, 3-(triethoxysilyl)propyl succinic anhydride, N-[5-(trimethoxysilyl)-2-aza-1-oxo-pentyl]caprolactam, 2-(trimethoxysilylethyl)pyridine, N-(trimethoxysilylethyl)benzyl-N,N,N-trimethylammonium chloride, phenylvinyldiethoxysilane, 3-thiocyanatopropyltriethoxysilane, (tridecafluoro-1,1,2,2-tetrahydrooctyl)triethoxysilane, N-{3-(triethoxysilyl)propyl}phthalamic acid, (3,3,3-trifluoropropyl)methyldimethoxysilane, (3,3,3-trifluoropropyl)trimethoxysilane, 1-trimethoxysilyl-2-(chloromethyl)phenylethane, 2-(trimethoxysilyl)ethylphenylsulfonyl azide, β-trimethoxysilylethyl-2-pyridine, trimethoxysilylpropyldiethylenetriamine, N-(3-trimethoxysilylpropyl)pyrrole, N-trimethoxysilylpropyl-N,N,N-tributylammonium bromide, N-trimethoxysilylpropyl-N,N,N-tributylammonium chloride, N-trimethoxysilylpropyl-N,N,N-trimethylammonium chloride, vinylmethyldiethoxysilane, vinyltriethoxysilane, vinyltrimethoxysilane, vinylmethyldimethoxysilane, vinyldimethylmethoxysilane, vinyldimethylethoxysilane, vinylmethyldichlorosilane, vinylphenyldichlorosilane, vinylphenyldiethoxysilane, vinylphenyldimethylsilane, vinylphenylmethylchlorosilane, vinyltriphenoxysilane, vinyltris-t-butoxysilane, adamantylethyltrichlorosilane, allylphenyltrichlorosilane, (aminoethylaminomethyl)phenethyltrimethoxysilane, 3-aminophenoxydimethylvinylsilane, phenyltrichlorosilane, phenyldimethylchlorosilane, phenylmethyldichlorosilane, benzyltrichlorosilane, benzyldimethylchlorosilane, benzylmethyldichlorosilane, phenethyldiisopropylchlorosilane, phenethyltrichlorosilane, phenethyldimethylchlorosilane, phenethylmethyldichlorosilane, 5-(bicycloheptenyl)trichlorosilane, 5-(bicycloheptenyl)triethoxysilane, 2-(bicycloheptyl)dimethylchlorosilane, 2-(bicycloheptyl)trichlorosilane, 1,4-bis(trimethoxysilylethyl)benzene, bromophenyltrichlorosilane, 3-phenoxypropyldimethylchlorosilane, 3-phenoxypropyltrichlorosilane, t-butylphenylchlorosilane, t-butylphenylchlorosilane, t-butylphenylmethoxysilane, t-butylphenyldichlorosilane, p-(t-butyl)phenethyldimethylchlorosilane, p-(t-butyl)phenethyltrichlorosilane, 1,3-(chlorodimethylsilylmethyl)heptacosane, ((chloromethyl)phenylethyl)dimethylchlorosilane, ((chloromethyl)phenylethyl) methyldichlorosilane, ((chloromethyl)phenylethyl)trichlorosilane, ((chloromethyl)phenylethyl)trimethoxysilane, chlorophenyltrichlorosilane, 2-cyanoethyltrichlorosilane, 2-cyanoethylmethyldichlorosilane, 3-cyanopropylmethyldiethoxysilane, 3-cyanopropylmethyldichlorosilane, 3-cyanopropyldimethylchlorosilane, 3-cyanopropyldimethylethoxysilane, 3-cyanopropylmethyldichlorosilane, and 3-cyanopropyltrichlorosilane.

With the above embodiment, the lower layer formation solution 25L and the upper layer formation solution 27L were formed by dissolving the hole transport layer formation material 25 s and the light emitting layer formation material 27 s in the lower layer solvent and the upper layer solvent, respectively, but the invention is not limited to this, and the hole transport layer formation material 25 s and the light emitting layer formation material 27 s may be dispersed in corresponding dispersion media, and these dispersion used as the lower layer formation solution 25L and the upper layer formation solution 27L, respectively.

With the above embodiment, the hole transport layer 25 of the organic EL display 10 contained the surfactant 26, but the invention is not limited to this, and may be constituted such that when the light emitting layer 27 is formed in the step of manufacturing the organic EL display 10, the hole transport layer 25 contains the surfactant 26 that is lyophilic with respect to the upper layer droplets 27D. Specifically, the surfactant 26 need only exhibit the property of enhancing wettability when the upper layer droplets 27D are formed, and need not manifest its surfactant capability when the hole transport layer 25 is formed, or after the light emitting layer 27 has been formed.

With the above embodiment, the laminated pattern was embodied as two layers, namely, the hole transport layer 25 and the light emitting layer 27, but is not limited to this, and may include a multiphoton structure in which these two layers are repeatedly laminated, or a plurality of thin film layers may be laminated, for example.

With the above embodiment, the organic EL display 10 was embodied as a bottom emission type, but is not limited to this, and may involve a top emission type instead. Alternatively, the light emitting layer 27 may be constituted as a lower thin film layer, and the surfactant 26 may be contained in this light emitting layer 27.

With the above embodiment, the hole transport layer formation material 25 s and the light emitting layer formation material 27 s were embodied as high-molecular weight organic materials, but are not limited to this, and conventional low-molecular weight materials may be used instead.

With the above embodiment, the organic EL layer 30 was constituted by the hole transport layer 25 and the light emitting layer 27, but the constitution may instead be such that an electron injection layer composed of laminated films of calcium and lithium fluoride, for example, is provided to the upper layer of this light emitting layer 27. Also, the electron injection layer here may be formed by droplets, and a surfactant contained in the light emitting layer 27.

With the above embodiment, the control element formation region 14 was equipped with the switching transistor T1 and the drive transistor T2, but is not limited to this, and the constitution may instead be such that a single transistor, or numerous transistors, or numerous capacitors are used, according to the desired element design.

With the above embodiment, the organic EL layer 30 was formed by an inkjet method, but the invention is not limited to this, and the method for forming the organic EL layer 30 may instead be such that, for example, the lower layer droplets 25D and the upper layer droplets 27D are formed by a liquid applied by spin coating or another such method, and the organic EL layer 30 is formed by drying and solidifying this liquid.

With the above embodiment, the microscopic lower layer droplets 25 b were discharged by the piezoelectric elements 39, but the invention is not limited to this, and a resistance heating element may be provided to the liquid supply chamber 37, for example, and the microscopic lower layer droplets 25 b may be discharged by bursting the bubbles formed by the heating of this resistance heating element.

With the above embodiment, the laminated pattern was embodied as the organic EL layer 30, but is not limited to this, and may instead be color filters of various colors, and may also be any of various wiring patterns of the scanning lines Lx or the data lines Ly, for example.

With the above embodiment, the electro-optical device was embodied as the organic EL display 10, but is not limited to this, and may instead be a backlight mounted in a liquid crystal panel, for example, or may be a field effect type of display (FED, SED, etc.) that is equipped with a flat electron emission element, and that utilizes the ability of a fluorescent substance to emit light as a result of the electrons emitted from this element.

This application claims priority to Japanese Patent Application No. 2004-362541. The entire disclosure of Japanese Patent Application No. 2004-362541 is hereby incorporated herein by reference. 

1. A patterned substrate, comprising an element formation surface; a laminated pattern having laminating patterns formed on the element formation surface by drying droplets containing a pattern formation material, wherein a lower layer pattern contains a surfactant that is lyophilic with respect to droplets that form an upper layer pattern.
 2. The patterned substrate according to claim 1, wherein the surfactant has: a functional group that is lyophilic with respect to the droplets that form the upper layer pattern; and a functional group that is lyophilic with respect to droplets that form the lower layer pattern.
 3. The patterned substrate according to claim 1, wherein the surfactant is an organic compound having a hydrophilic functional group and a lipophilic functional group.
 4. The patterned substrate according to claim 1, wherein the surfactant is either a silane coupling agent having a functional group that is lyophilic with respect to the droplets that form the upper layer pattern, or a hydrolyzate of the silane coupling agent.
 5. The patterned substrate according to claim 1, wherein the pattern formation material is a light emitting element formation material, and the laminated pattern is a light emitting element. 